A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries
The tool is a key component in the Friction Stir Welding (FSW) process, but the tool degrades and changes shape during use; however, only a limited number of experimental studies have been undertaken in order to understand the effect that worn tool geometry has on the material flow and resultant wel...
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| Format: | Article |
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Elsevier
2015
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| Online Access: | https://eprints.nottingham.ac.uk/35530/ |
| _version_ | 1848795099471806464 |
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| author | Hasan, Ahmed Bennett, Chris Shipway, P.H. |
| author_facet | Hasan, Ahmed Bennett, Chris Shipway, P.H. |
| author_sort | Hasan, Ahmed |
| building | Nottingham Research Data Repository |
| collection | Online Access |
| description | The tool is a key component in the Friction Stir Welding (FSW) process, but the tool degrades and changes shape during use; however, only a limited number of experimental studies have been undertaken in order to understand the effect that worn tool geometry has on the material flow and resultant weld quality. In this study, a validated model of the FSW process is generated using the CFD software FLUENT, with this model then being used to assess the detail of the differences in the flow behaviour, mechanically affected zone (MAZ) size and strain rate distribution around the tool for both unworn and worn tool geometries. Comparisons are made at two different tool rotational speeds using a single weld traverse speed. The study shows that there are significant differences in the flow behaviour around and under the tool when the tool is worn. This modelling approach can therefore be used to improve understanding of the effective limits of tool life for welding, with a specific outcome of being able to predict and interpret the behaviour when using specific weld parameters and component geometry without the need for experimental trials. |
| first_indexed | 2025-11-14T19:26:42Z |
| format | Article |
| id | nottingham-35530 |
| institution | University of Nottingham Malaysia Campus |
| institution_category | Local University |
| last_indexed | 2025-11-14T19:26:42Z |
| publishDate | 2015 |
| publisher | Elsevier |
| recordtype | eprints |
| repository_type | Digital Repository |
| spelling | nottingham-355302020-05-04T17:15:28Z https://eprints.nottingham.ac.uk/35530/ A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries Hasan, Ahmed Bennett, Chris Shipway, P.H. The tool is a key component in the Friction Stir Welding (FSW) process, but the tool degrades and changes shape during use; however, only a limited number of experimental studies have been undertaken in order to understand the effect that worn tool geometry has on the material flow and resultant weld quality. In this study, a validated model of the FSW process is generated using the CFD software FLUENT, with this model then being used to assess the detail of the differences in the flow behaviour, mechanically affected zone (MAZ) size and strain rate distribution around the tool for both unworn and worn tool geometries. Comparisons are made at two different tool rotational speeds using a single weld traverse speed. The study shows that there are significant differences in the flow behaviour around and under the tool when the tool is worn. This modelling approach can therefore be used to improve understanding of the effective limits of tool life for welding, with a specific outcome of being able to predict and interpret the behaviour when using specific weld parameters and component geometry without the need for experimental trials. Elsevier 2015-08-08 Article PeerReviewed Hasan, Ahmed, Bennett, Chris and Shipway, P.H. (2015) A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries. Materials & Design, 87 . pp. 1037-1046. ISSN 0264-1275 Friction Stir Welding; Computational fluid dynamics; Flow; Modelling; Wear http://www.sciencedirect.com/science/article/pii/S0264127515302665 doi:10.1016/j.matdes.2015.08.016 doi:10.1016/j.matdes.2015.08.016 |
| spellingShingle | Friction Stir Welding; Computational fluid dynamics; Flow; Modelling; Wear Hasan, Ahmed Bennett, Chris Shipway, P.H. A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries |
| title | A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries |
| title_full | A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries |
| title_fullStr | A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries |
| title_full_unstemmed | A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries |
| title_short | A numerical comparison of the flow behaviour in Friction Stir Welding (FSW) using unworn and worn tool geometries |
| title_sort | numerical comparison of the flow behaviour in friction stir welding (fsw) using unworn and worn tool geometries |
| topic | Friction Stir Welding; Computational fluid dynamics; Flow; Modelling; Wear |
| url | https://eprints.nottingham.ac.uk/35530/ https://eprints.nottingham.ac.uk/35530/ https://eprints.nottingham.ac.uk/35530/ |